Method and installation for producing a portion capsule, and portion capsule for beverages and foodstuffs

ABSTRACT

The invention relates to a method for producing a portion capsule (2) for drinks and food products having a cup-shaped bowl (3) comprising a seal edge (30), a (31) and a covering face (32) and having a cup-base shaped filter element (4) which is inserted into the bowl (2) and in which a product is introduced, comprising the steps of: (a) forming a filter element (4) from a forming piece (42) comprising a filter material; (b) inserting the filter element (4) formed into a cup-shaped bowl (3); (c) connecting an edge of the formed filter element (4) to a seal edge (30) of the cup-shaped bowl (3); and (d) connecting the filter element (4) to the base (31) and/or the covering face (32) of the bowl (3). The invention further relates to an installation (1) for producing a portion capsule (2) and a portion capsule (2) for drinks and food products.

FIELD OF APPLICATION AND PRIOR ART

The invention relates to a method and an installation for producing aportion capsule for drinks and food products having a cup-shaped bowland having a cup-shaped filter element which is inserted into the bowl.The invention further relates to a portion capsule for drinks and foodproducts.

Portion capsules for drinks or other food products are known from theprior art. The cup-shaped bowl is preferably formed in atruncated-cone-like manner or cylindrically and has a base and acovering face. It is produced, for example, from a deep-drawn plasticsfilm or with the plastic material injection-molding method. At a sideopposite the base, there are provided a filling opening and a seal edgewhich surrounds the filling opening and on which a covering film isapplied, in particular sealed, after the portion capsule has beenfilled.

In order to produce specific drinks or food products, a filter elementhas to be inserted into the portion capsule.

An installation for producing a portion capsule having a filter elementis known, for example, from EP2093148 A1, wherein the installation has asingle forming and inserting device in order to form in one stepindividual cup-shaped filters which comprise a filter material and toinsert each of these cup-shaped filters into a bowl, and wherein thereis provided downstream of this forming and inserting device a weldingdevice, by means of which an edge of each cup-shaped filter is welded toan upper seal edge of the associated bowl.

Problem and Solution

Objectives of the invention are to provide a method and an installationfor producing a portion capsule which is improved for subsequenthandling and an improved portion capsule.

These objectives are achieved by the aspects of subject-matter havingthe features of claims 1, 6 and 11. Advantageous embodiments aredescribed in the dependent claims.

According to a first aspect, there is provided a method for producing aportion capsule for drinks and food products having a cup-shaped bowlcomprising a seal edge, a base and a covering face and having a cup-shaped filter element which is inserted into the bowl and in which aproduct is introduced, comprising the steps of: (a) forming a filterelement from a forming piece comprising a filter material; (b) insertingthe filter element formed into a cup-shaped bowl; (c) connecting an edgeof the formed filter element to a seal edge of the cup-shaped bowl; and(d) connecting the filter element to the base and/or the covering faceof the bowl.

By the filter element being connected to the base and/or the coveringface of the bowl, subsequent handling is improved. In this instance, theconnection locations are preferably selected so that separation of thefilter element is not carried out when the portion capsule is piercedduring use for dispensing the drink.

Connection of the filter element to the seal edge of the bowl and/or thebase or the covering face is preferably carried out by means of anadhesive, melt or seal connection.

In one embodiment, simultaneous connection of the filter element to theseal edge and the base or the covering face is carried out. Inadvantageous embodiments, steps c) and d) were carried out separately.

In this case, in an advantageous embodiment there is provision for thefilter element to be preformed in step a), wherein the preformed filterelement is brought into a definitive form before or during step d).

In an embodiment, the forming piece is stamped or cut out from amaterial web and formed in one step. In advantageous embodiments,however, there is provision for the forming piece to be stamped or cutout of a material web before step a), that is to say, before the filterelement is formed, in a separate step.

The bowl is preferably transported during the method in a product flowdirection. In this case, there is preferably provision for seriesproduction for a plurality of portion capsules to be producedsimultaneously, wherein a plurality of filter elements aresimultaneously inserted into a plurality of bowls which are arranged onebehind the other in the product flow direction or beside each othertransversely, preferably perpendicularly, to the product flow direction,and each to be connected to the associated bowl.

In one embodiment, the bowls are provided by deep-drawing from amaterial web, wherein a plurality of bowls are connected to each otherat the seal edges thereof.

In an advantageous embodiment, after the filter element is inserted andthe filter element is connected to the base or the covering face of thebowl, embossing is carried out. The portion capsules which are separatedafter the connection have improved handling in comparison withconventional portion capsules. By the bowls being stamped out after thefilter elements are inserted and fixed, an edge of the filter element isalso prevented from projecting beyond a seal edge of the bowl in afinished portion capsule.

According to a second aspect, an installation is provided for producinga portion capsule for drinks and food products having a cup-shaped bowlcomprising a seal edge, a base and a covering face and having acup-shaped filter element which is inserted into the bowl and in which aproduct can be introduced, comprising a first device, in particular afold-forming member, for forming a filter element from a forming piececomprising a filter material, a second device for inserting the formedfilter element into a cup-shaped bowl, a third device, in particular aseal device, for fitting an edge of the formed filter element to a sealedge of the cup-shaped bowl, and a fourth device, in particular a sealdevice, for fitting the filter element to the base and/or the coveringface of the bowl.

In this case, the devices can be constructed partially together. Thus,it is conceivable for the first and second devices to have a common toolfor insertion and fitting, in particular sealing the filter element tothe seal wall. Similarly, it is conceivable for the third and fourthdevices a common tool for simultaneously fitting the filter element tothe seal edge and to the base or the covering face of the bowl. Inadvantageous embodiments, the second and the third devices have a commontool for inserting the formed filter element into the cup-shaped bowland connecting the filter element to the seal edge of the bowl. In otherembodiments, all the devices are constructed separately, wherein thebowl or a plurality of bowls is/are transported to the devicessuccessively in a product flow direction.

In an embodiment, the filter element can be brought into a definitiveform by means of the first device. In advantageous embodiments, there isprovided after the first device and before or at the fourth device aforming tool, by means of which the filter element inserted into thebowl can be brought into a definitive form before or during the fittingof the filter element to the base and/or the covering face of the bowl.By formation in the bowl, an optimum formation of the filter element isensured.

In an embodiment, the first device is constructed in such a manner thatstamping and forming of the filter element are carried out by means ofthe first device. In advantageous embodiments, a stamping or cuttingdevice for stamping or cutting out the forming piece from a material webis provided in the product flow direction upstream of the first device.

There is preferably provided a transport device, by means of which bowlor in series production a large number of bowls can be transported inthe product flow direction during production of the portion capsule. Thebowls are preferably connected to each other in the product flowdirection.

In advantageous embodiments, the installation has a stamping devicedownstream of the device for fitting the filter element to the baseand/or the covering face of the bowl, wherein the bowl with the filterelement inserted can be brought into a final form by means of thestamping device and/or the bowls which are connected to each other canbe separated.

According to a third aspect, a portion capsule for drinks and foodproducts having a cup-shaped bowl is provided, comprising a seal edge, abase and a covering face and having a cup-shaped filter element which isinserted into the bowl and in which a product can be introduced, whereinan edge of the filter element is connected to the seal edge of thecup-shaped bowl and wherein the filter element is connected to the baseand/or the covering face of the bowl.

BRIEF DESCRIPTION OF THE DRAWINGS

Additional advantages and aspects of the invention will be appreciatedfrom the claims and the following description of preferred exemplaryembodiments of the invention which are explained below with reference tothe Figures, in which:

FIG. 1 shows an embodiment of a portion capsule;

FIG. 2 shows an embodiment of an installation for producing a portioncapsule according to FIG. 1; and

FIG. 3 shows a packaging line for producing, filling and packaging theportion capsules illustrated in FIG. 1.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

FIG. 1 is a schematic view of a portion capsule 2 for drinks and foodproducts having a cup-shaped bowl 3 and a cup-shaped filter element 4which is inserted into the bowl and in which a product which is notillustrated can be introduced.

The bowl 3 has a seal edge 30, a base 31 and a covering face 32. Thefilter element 4 is connected at the free edge 40 thereof to the sealedge 30 of the cup-shaped bowl 3, for example, sealed thereto.Furthermore, the filter element 4 is connected to the base 31 of thebowl 3, for example, sealed thereto.

FIG. 2 schematically shows an installation 1 for producing a portioncapsule 2 according to FIG. 1 having a cup-shaped bowl 3 and a filterelement 4. A product flow direction is schematically indicated by anarrow.

The installation 1 comprises a transport device 10, by means of whichthe cup-shaped bowls 3 are transported in the product flow direction.The transport device 10 is preferably constructed in such a manner thata plurality of bowls 3 are conveyed in parallel rows in the product flowdirection. The bowls 3 are preferably connected to each other at theseal edges 30 in the product flow direction.

The installation 1 comprises in the product flow direction a device 12for inserting a filter element 4 into a bowl 3 and a device 13 forconnecting a free edge 40 (cf. FIG. 1) of the filter element 4 to a sealedge 30 of the bowl 3. The edge 40 of the filter element 4 is fitted tothe seal edge 30 of the bowl 3, preferably by means of an adhesive, meltor seal connection. The insertion of the filter element 3 into the bowl3 and connection of the filter element 4 to the seal edge 30 of the bowlare carried out depending on the configuration in one step by means of acommon tool or in two steps using different tools.

The installation 1 further comprises a forming device 14, by means ofwhich the preformed filter element 4 is formed in the bowl 3 and a sealdevice 15, by means of which the filter element 4 is fixed to a base 31and/or a covering face 32 of the bowl 3, in particular sealed to thebase 31 and/or the covering face 32.

In the embodiment illustrated, the forming device 14 and the seal device15 have a common tool. In other embodiments, two separate tools areprovided. In still other embodiments, an additional forming device 14for forming the filter elements 4 is dispensed with.

Downstream of the forming device 14 and the seal device 15 in theproduct flow direction, a stamping device 16 is provided, wherein thebowls 3 are stamped by means of the stamping device 16 together with thefilter elements 4 which are fitted thereto to produce a desired form andsize. If the bowls 3 are connected to each other at the edges thereof,the bowls are separated from each other by means of the stamping device16.

The filter elements 4 are prefabricated before insertion. To this end,the installation comprises a filter separation or stamping device 18, bymeans of which forming pieces 42, for example, round blanks, for thefilter elements 4 are stamped or cut out of a material web of the filtermaterial which is supplied from a store 44. Finally, the installation 1further comprises a fold-forming member 19, by means of which theforming pieces 42 are preformed from the filter material before orduring insertion into the bowls 2.

As schematically indicated, residual material portions are supplied to achopper 5 or a different type of waste processing.

In a method carried out by means of the installation 1 according to FIG.2 for producing a portion capsule 2, the following steps are preferablyprovided for:

1. stamping or cutting out a forming piece 42 from a filter material bymeans of the filter separation or stamping device 18;

2. forming a filter element 4 from the forming piece 42 by means of thefold-forming member 19;

3. inserting the formed filter element 4 into a cup-shaped bowl 3 bymeans of the device 12 for inserting a filter element 4 into a bowl 3;

4. connecting an edge 40 of the formed filter element 4 to a seal edge30 of the cup-shaped bowl 3 by means of the device 13 for connecting afree edge 40 of the filter element 4 to a seal edge 30 of the bowl 3;

5. forming the filter element 42 into a final form in the bowl 3 bymeans of the forming device 14;

6. connecting the filter element 4 to the base 31 and/or the coveringface 32 of the bowl 3 by means of the seal device 15; and

7. stamping the bowl 3 with the filter element 4 inserted and connectedby means of a stamping device 16.

As described above, in this instance there may be provision forindividual steps to be carried out together. In particular, steps 3 and4 and/or steps 5 and 6 are preferably carried out with a common tool.

FIG. 3 schematically shows a packaging line for producing, filling andpackaging portion capsules 2 which are not illustrated in FIG. 3. Thepackaging line comprises the installation 1 according to FIG. 2 forproducing the portion capsules 2 including the filter elements 4 whichare inserted therein. In the product flow direction which is indicatedby an arrow, a work station 102 is provided downstream of theinstallation 1 for filling the portion capsules. A store 101 is providedbetween the installation 1 and the work station 102 for filling. Thepackaging line illustrated further comprises a first cartoning device103, a second cartoning device 104 for inserting into a surroundingcarton and a palletizing device 105. The individual work stations 1,102, 103, 104, 105 are connected to each other via suitable transportpaths.

The packaging line is merely exemplary and the individual work stations,in particular the installation 1 for producing the portion capsules 2with a filter element 4, can be combined with other work stations and/orin other arrangements.

1. A method for producing a portion capsule for drinks and food productshaving a cup-shaped bowl comprising a seal edge, a base and a coveringface and having a cup-shaped filter element which is inserted into thebowl and in which a product is introduced, comprising the steps of: a)forming a filter element from a forming piece comprising a filtermaterial; b) inserting the filter element formed into a cup-shaped bowl;c) connecting an edge of the formed filter element to a seal edge of thecup-shaped bowl; and d) connecting the filter element to the base and/orthe covering face of the bowl.
 2. The method as claimed in claim 1,wherein the filter element is preformed in step a), wherein thepreformed filter element is brought into a definitive form before orduring step d).
 3. The method as claimed in claim 1, wherein the formingpiece is stamped or cut out from a material web before step a).
 4. Themethod as claimed in claim 1, wherein the bowl is transported during themethod in a product flow direction, wherein preferably a plurality ofbowls are connected to each other in the product flow direction in stepsa) to d).
 5. The method as claimed in claim 4, further comprising thestep of e) embossing the bowl with the filter element inserted.
 6. Aninstallation for producing a portion capsule for drinks and foodproducts having a cup-shaped bowl comprising a seal edge, a base and acovering face and having a cup-shaped filter element which is insertedinto the bowl and in which a product can be introduced, comprising: afirst device, in particular a fold-forming member, for forming a filterelement from a forming piece comprising a filter material; a seconddevice for inserting the formed filter element into a cup-shaped bowl; athird device, in particular a seal device, for fitting a seal edge ofthe formed filter element to a seal edge of the cup-shaped bowl; and afourth device, in particular a seal device, for fitting the filterelement to the base of the bowl.
 7. The installation as claimed in claim6, wherein there is provided before or at the fourth device a formingtool, by means of which the filter element inserted into the bowl can bebrought into a definitive form before or during the fitting of thefilter element to the base and/or the covering face of the bowl.
 8. Theinstallation as claimed in claim 6, wherein a stamping or cutting devicefor stamping or cutting out the forming piece from a material web isprovided in the product flow direction upstream of the first device. 9.The installation as claimed in claim 6, wherein there is provided atransport device, by means of which the bowl can be transported in theproduct flow direction during production of the portion capsule, whereina plurality of bowls are preferably connected to each other in theproduct flow direction.
 10. The installation as claimed in claim 6,wherein there is provided a stamping device downstream of the device forfitting the filter element to the base of the bowl, wherein the bowlwith the filter element inserted can be brought into a final form bymeans of the stamping device.
 11. A portion capsule for drinks and foodproducts having a cup-shaped bowl, comprising a seal edge, a base and acovering face and having a cup-shaped filter element which is insertedinto the bowl and in which a product can be introduced, wherein an edgeof the filter element is connected to the seal edge of the cup-shapedbowl, wherein the filter element is connected to the base and/or thecovering face of the bowl.